Method and apparatus for providing omnidirectional lighting in a scanning device

ABSTRACT

Systems and methods are provided for selectively controlling the illumination, and particularly dark field illumination, applied to a symbol to be decoded, and for determining a suitable or optimized level of lighting for decoding the symbol. A method includes providing a light source comprising a plurality of individually-controllable lighting elements for providing low angle dark field illumination; activating an image sensor for detecting image data reflected from an encoded data symbol when the encoded data symbol is illuminated by the light source; and providing a controller connected to each of the individually-controllable lighting elements, the controller being programmed for: selectively activating the individually-controllable lighting elements to vary the direction of the low angle dark field illumination provided by the light source; and processing the image data detected by the image.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.12/552,107, filed on Sep. 1, 2009, now U.S. Pat. No. 8,061,613, andentitled “Method And Apparatus For Providing Omnidirectional Lighting InA Scanning Device,” which is a continuation of U.S. patent applicationSer. No. 10/911,989, filed on Aug. 5, 2004, now U.S. Pat. No. 7,604,174,and entitled “Method And Apparatus For Providing OmnidirectionalLighting In A Scanning Device,” which is a continuation-in-part of U.S.patent application Ser. No. 10/693,626 filed Oct. 24, 2003 now U.S. Pat.No. 7,826,783 entitled “Light Pipe Illumination System and Method,” eachof which are hereby incorporated by reference.

FIELD OF THE INVENTION

This invention relates to illuminators and more particularly toilluminators for image acquisition devices and machine vision systems.

BACKGROUND OF THE INVENTION

Machine vision systems use image acquisition devices that include camerasensors to deliver information on a viewed subject. The system theninterprets this information according to a variety of algorithms toperform a programmed decision-making and/or identification function. Foran image to be most-effectively acquired by a sensor in the visible, andnear-visible light range, the subject should be properly illuminated.

In the example of barcode scanning using an image sensor, good lightingis highly desirable. Barcode scanning entails the aiming of an imageacquisition sensor (CMOS camera, CCD, etc.) at a location on an objectthat contains a bar code, and retrieval of an image of that barcode. Thebar code contains a set of predetermined patterns that represent anordered group of characters or symbols from which an attached dataprocessor (for example a microcomputer) can derive useful informationabout the object (e.g. its serial number, type, model, price, etc.).Barcodes are available in a variety of shapes and sizes. Two of the mostcommonly employed barcode types are the so-called one-dimensionalbarcode, consisting a line of vertical stripes of varying width andspacing, and the so-called two-dimensional barcode consisting of atwo-dimensional array of dots or rectangles.

In reading barcodes or other subjects of interest the type ofillumination employed is of concern. Where barcodes and other viewedsubjects are printed on a flat surface with contrasting ink or paint, adiffuse, high-angle “bright field” illumination may best highlight thesefeatures for the sensor. By high-angle it is meant, generally, lightthat strikes the subject nearly perpendicularly (normal) or at an anglethat is typically no more than about 45 degrees from perpendicular(normal) to the surface of the item being scanned. Such illumination issubject to substantial reflection back toward the sensor. By way ofexample, barcodes and other subjects requiring mainly bright fieldillumination may be present on a printed label adhered to an item orcontainer, or on a printed field in a relatively smooth area of item orcontainer.

Conversely, where a barcode or other subject is formed on amore-irregular surface or is created by etching or peening a patterndirectly on the surface, the use of highly reflective bright fieldillumination may be inappropriate. A peened/etched surface hastwo-dimensional properties that tend to scatter bright fieldillumination, thereby obscuring the acquired image. Where a viewedsubject has such decidedly two-dimensional surface texture, it may bebest illuminated with dark field illumination. This is an illuminationwith a characteristic low angle (approximately 45 degrees or less, forexample) with respect to the surface of the subject (i.e. an angle ofmore than approximately 45 degrees with respect to normal). Using suchlow-angle, dark field illumination, two-dimensional surface texture iscontrasted more effectively (with indents appearing as bright spots andthe surroundings as shadow) for better image acquisition.

To take full advantage of the versatility of a camera image sensor, itis desirable to provide both bright field and dark field illuminationfor selective or simultaneous illumination of a subject. However, darkfield illumination must be presented close to a subject to attain thelow incidence angle thereto. Conversely, bright field illumination isbetter produced at a relative distance to ensure full area illumination.

In addition, a current-production sensor may have a resolution of640×480 (over 300 K) or 1280×1024 (over 1.3 M) pixels within its nativefield of view. This resolution is desirable for attaining an accurateimage of the subject. However, processing speed may be compromised bythe need to acquire every pixel in the field of view even if the subjectis a relatively small part of that field (for example, the narrow stripof a one-dimensional barcode). If the field of view is to be narrowed toonly encompass an area of interest, then a system for aiming the cameraonto that area of interest is desirable. Likewise, where a given fieldof view may contain multiple codes or subjects, the ability to focusupon particular parts of that field of view to discern the selectedsubject is also desirable.

SUMMARY OF THE INVENTION

In one aspect, the present invention provides a method for decoding anencoded data symbol. The method comprises steps including providing alight source comprising a plurality of individually-controllablelighting elements for providing low angle dark field illumination;activating an image sensor for detecting image data reflected from anencoded data symbol when the encoded data symbol is illuminated by thelight source; and providing a controller connected to each of theindividually-controllable lighting elements, the controller beingprogrammed for: selectively activating the individually-controllablelighting elements to vary the direction of the low angle dark fieldillumination provided by the light source; and processing the image datadetected by the image.

In another aspect of the invention, a method for decoding an encodeddata symbol is provided comprising steps including (a) providing aplurality of individually-controllable lighting elements arranged aroundthe encoded data symbol to provide low-angle dark field illumination;(b) providing a bright field illuminator directed at the encoded datasymbol to provide bright field illumination; (c) selectivelyilluminating the encoded data symbol with at least one of theindividually-controllable lighting elements; (d) acquiring an image dataset; (e) evaluating the image data set for determining suitability fordecoding; (f) selectively varying a lighting parameter for varying thelight emitted from the individually-controllable lighting elements tovary the direction of the low-angle dark field illumination on theencoded data symbol and selectively activating the bright fieldilluminator; and (g) repeating steps (e) and (f) until the image dataset is suitable for decoding.

In yet another aspect, the present invention provides a methodcomprising the steps of using a ring light source, projecting low angledark field illumination to an adjacent surface including a symbol to bedecoded; providing a controller connected to the ring light source andusing the controller for selectively varying the direction of the lowangle dark field illumination provided from the ring light source; usingan image sensor connected to the controller, the image sensor acquiringimage data of the symbol, wherein the controller is programmed for:evaluating the acquired image data and determining whether the imagedata is sufficient to decode the symbol; and varying the light projectedfrom the ring light source until the image data is sufficient to decodethe symbol.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention description below refers to the accompanying drawings, ofwhich:

FIG. 1 is a perspective view of a handheld scanning system and subjectemploying a passive light pipe illuminator according to an embodiment ofthis invention;

FIG. 2 is a perspective view of a fixedly mounted scanning system andsubject employing a passive light pipe illuminator according to anembodiment of this invention;

FIG. 3 is a schematic cross section of a passive light pipe and ringilluminator according to an embodiment of this invention;

FIG. 3A is a perspective view of a handheld scanning system including alight pipe and illumination ring having an arc configuration;

FIG. 4 is a side cross section of a sensor with dark field illuminatingpassive light pipe according to an embodiment of this invention;

FIG. 5 is a side cross section of a sensor with bright fieldilluminating passive light pipe and aiming illuminators according to anembodiment of this invention;

FIG. 6 is a plan view of a circular illumination pattern projected bythe illuminating light pipe of FIG. 5;

FIG. 7 is a plan view of a rectangular/square illumination patternprojected by the illuminating light pipe of FIG. 5, encompassing thesensor's full field of view;

FIG. 8 is a side cross section of a sensor with bright fieldilluminating passive light pipe, nested within a dark field illuminatingpassive light pipe and aiming illuminators according to an embodiment ofthis invention;

FIG. 9 is a perspective view of a handheld scanning system employing apassive light pipe that illuminates a modified or restricted sensorfield of view according to an alternate embodiment;

FIG. 10 is a plan view of a rectangular illumination pattern projectedby the illuminating light pipe of FIG. 9, encompassing amodified/restricted sensor field of view;

FIG. 11 is a side cross section of the sensor and passive light pipeilluminator that can be used to generate a predetermined bright fieldpattern such as, for example that of FIG. 9;

FIG. 12 is a plan view of a dark field illuminating active light pipeaccording to another embodiment of the invention;

FIG. 13 is a side cross section of a sensor with the dark fieldilluminating active light pipe of FIG. 12;

FIG. 14 is a block diagram of a control system of a scanning deviceincluding an illumination ring constructed in accordance with any of theembodiments shown; and

FIG. 15 is a flow chart of illustrating steps for selecting lightingparameters by the control system of FIG. 14.

DETAILED DESCRIPTION OF AN ILLUSTRATIVE EMBODIMENT

FIG. 1 shows a scanning system 100 adapted for handheld operation. Anexemplary handheld scanning appliance or handpiece 102 is provided. Itincludes a grip section 104 and a body section 106. The sensor and otherfunctional components described herein can be controlled and can directimage data to an onboard embedded processor 109. This processor caninclude a scanning software application 113 by which lighting iscontrolled, images are acquired and image data is interpreted intousable information (for example, alphanumeric strings derived from thebarcode images). The decoded information can be directed via a cable 110to a PC or other data storage device 112 having (for example) a display114, keyboard 116 and mouse 118, where it can be stored and furthermanipulated using an appropriate application 120. Alternatively, thecable 110 can be directly connected to an interface in the scanningappliance and an appropriate interface in the computer 112. In this casethe computer-based application 120 performs various image interpretationand lighting control functions as needed. The precise arrangement of thehandheld scanning appliance with respect to an embedded processor,computer or other processor is highly variable. For example, a wirelessinterconnect can be provided in which no cable 110 is present. Likewise,the depicted microcomputer can be substituted with another processingdevice, including an onboard processor or a miniaturized processing unitsuch as a personal digital assistant or other small-scale computingdevice.

The scanning application 113 can be adapted to respond to inputs fromthe scanning appliance 102. For example, when the operator toggles atrigger 122 on the appliance 102, an internal camera image sensor (150,shown and described further below) acquires an image of a region ofinterest 130 on an item 132. The exemplary region of interest includes atwo-dimensional bar code 134 that can be used to identify the part 132.Identification and other processing functions are carried out by thescanning application 113, based upon image data transmitted from theappliance 102 to the processor 109.

Simultaneously with, or in advance of acquisition of the image, the areaof interest 130 is illuminated. In one embodiment, a switch 140 on theappliance 102 can be used to operate the illuminator, which consists ofa novel light pipe arrangement 142 in accordance with this invention.Alternatively, as will be described below, the operation of theilluminator can be operated and controlled remotely by the scanningsoftware application 120. The passive light pipe 142 consists of anextended barrel of light transmissive material terminating (in thisembodiment) in an angled tip 144. As described further below, this tipis designed to cause internal reflection that projects a low-angle darkfield illumination in the area of interest 130. As noted above, suchdark field illumination is typically provided at an angle of no morethan approximately 45 degrees with respect to the surface or more than45 degrees normal to the optical axis. Extending through the center ofthe light pipe, which comprises a hollow tube, is a camera sensor 150(shown in phantom and associated optics). The focal point of the camerais selected so that it is able to focus on the desired area of interest,as its field of view, in close proximity to the tip 144. In this manner,the tip can be placed very close to, or in contact with the area ofinterest for accurate viewing. As noted above, the bar code 134 in thisembodiment is one that is best viewed using a dark field illumination.However, as will be described further below, the light pipes describedin accordance with this invention also has the ability to provide brightfield illumination for bar codes that are better suited to direct,high-angle illumination (for example, those printed with high contrastink on a relatively smooth, matte surface).

FIG. 2 shows another implementation of the light pipe in accordance withan embodiment of this invention. An embedded processor 109 and/orcomputer 112 and associated applications 113 and/or 120 similar to thosedescribed above can be employed. An associated cable 210 interconnectsthe computer, via an interface, with a camera element 220. The cameraelement can be a conventional camera mounted on a fixed bracket 222. Itincludes a lens and electro-optical sensor assembly 224 (shown inphantom). The light pipe is removably mounted via a securing ring 226with exemplary securing screws 228 in this embodiment. Note, whilescrews 228 are use, any fastener system can be substituted. A cable 230,shown in phantom, interconnects an internal ring illuminator, integralwith light pipe, to either the processor 109 or the computer 112. Thisarrangement allows the light pipes of this invention to be secured as aretrofit to a variety of preexisting cameras. In any of the embodimentsherein, the illuminator can be integrated with the camera's standardoperating functions, such as its strobe and trigger mechanisms, or itcan be controlled via the scanning application. Separate controlcircuitry (see FIGS. 14 and 15) can also be provided to modulate certainfunctions of the illuminator as described further below. In the exampleof FIG. 2, the illuminator is viewing parts or other items 260 movingalong a conveyer 262. The area of interest 264 is a bar code that isbest viewed using, for example, bright field illumination. As describedbelow, the light pipe arrangement, in accordance with the variousembodiments of this invention, can accommodate bright field illuminationas well as dark field illumination. In both FIGS. 1 and 2, and otherfigures described herein, the image sensor is, typically, a commerciallyavailable CMOS or CCD image sensor with a resolution of, for example,640×480 pixels or 1280×1024 pixels. Other resolutions and sensor typesare expressly contemplated, however.

With reference to FIG. 3, a version of the light pipe 310 described inFIGS. 1 and 2 is shown. This light pipe includes an outer tube 312 and anested, inner tube 314. The innermost wall of the inner tube 314defines, in this example, a circular lumen or channel. This channel is apath through which light can pass from the area of interest 320 to aboard-mounted or separately placed sensor 330. The lumen has a diameterWL that is equal to or greater than the diameter of the optics of thecamera sensor. In this embodiment, note that the sensor is mounted on acircuit board 332 that also includes the ring illuminator 334. This ringilluminator consists of an outer ring of LEDs or other appropriate lightsources 336 and an inner ring 338 of LEDs or other appropriate lightsources. The number of light sources, size of the rings and their shapeare highly variable. Thus, the term “ring” should be taken broadly todescribe a variety of regular and irregular curved (ovular, etc.) and/orpolygonal (rectangular, square, etc.) perimeter shapes. For example, insome applications, a rectangular or oval illumination pipe can be used,providing a reader having a profile that is less tall than it is wide.In these types of configurations, and particularly in ovalconfigurations, the dark field region extends to a distance from the endof the tube that is proportional to the width of the tube. When the pipeis twice as wide as it is tall, for example, the angle of illuminationfrom the sides of the light pipe causes the light to meets at a distancefurther from the end of the pipe than the light from the top and bottom.Therefore the dark field illumination extends further from the pipe,providing an enhanced, larger field of dark field illumination. Inaddition to this advantage, the oval and rectangular shape can beadvantageous as it reduces the overall size of the light pipe, and,further, can be stronger and more rugged in construction. Furthermore,the shape of the pipe can be selected based on the size and shape of thesymbol to be decoded, as described with reference to FIG. 9, below.

In general, the ring illuminator's light sources are placed relativelyclose to the outer perimeter of the sensor and/or its optics and thenumber of sources is sufficient to fill in the illumination field andsupply appropriate light to the subject. In general, any group of lightsources or one or more continuous sources (e.g. tubes) arranged to lighta perimeter of any size/shape can be broadly considered to be a “ring”light source herein.

Returning again to FIG. 3, in one embodiment, the ring can define acircle that is approximately 2-3 inches in outer diameter. Each ring isaligned with respect to one of the light pipes 312 and 314. As describedbelow, appropriate baffles separate the rings from each other so thatlight from one ring does not leak into the other ring. Referring stillto FIG. 3, the outer LED ring 336 can also be divided intoindividually-controllable segments. Here, the illumination ring 336 isshown as having has four exemplary segments that represent the quadrants380, 382, 384 and 386 of the overall circumference each of which areconnected to a lighting controller 370. The ring 336, as well as otherlight ring components described below, can be segmented into any numberof individually controllable elements to provide improved lightingconditions, also as described below.

Referring now to FIG. 3A, an alternative embodiment of an illuminator100 having a light pipe 311 and an arcuate illuminator 383 which extendsover only a portion of a full ring is shown. The partial ring arcedlight pipe 311 and arcuate illuminator 383 are particularly useful forilluminating small areas, where, for example, a full light pipe cannotbe brought close enough to the symbol to be illuminated. Situations inwhich these types of light pipes are useful include, for example, whereit is necessary to illuminate a symbol positioned on or near a corner,in a seam, or on a round or curved surface.

Referring again also to FIG. 3, as noted, each passive light pipe isconstructed from a light-transmissive material. This material can beacrylic, glass, or any other material capable of acting as a wave guidefor visible and near-visible light. The wall thickness of each pipe mayvary. In general, thicknesses are between approximately ⅛ inch and ¼inch. However, larger or smaller thicknesses are expressly contemplated.The overall length of the outer light pipe is also highly variable. Asnoted above, it is set so that the focus on the desired field of view isattained near, but beyond, the end of the tip 340. In one embodiment,the outer light pipe has a length of approximately 3-4 inches. The innerlight pipe 314 can be approximately the same length as the outer lightpipe, but in this embodiment, the inner light pipe is recessed withrespect to the outer, as shown, so that light can exit from the inneredge of the tip 340. The tip's light-transmissive region is shown by thedashed line 342. This inner edge light outlet can be formed by exposingand/or polishing a strip in the otherwise opaque overall surface of theouter light pipe 312. This light transmissive strip or region can extend(for example) ¼ inch, more or less, as shown by thickness T. Thethickness T is variable. Due to internal reflection caused by the angledportion 350 of the tip 340, low angle illumination 352 exits from theopen region 342. Similarly, the open tip 360 of the inner light pipe 314facilitates direct, bright field illumination 362 on the area ofinterest 320. The mechanics of the nested light pipe 310 are describedin further detail below. Reference will first be made to FIG. 4, whichdescribes, more particularly, a dark field illuminator. Reference willalso be made generally to the ring illuminator 334 and controller 370 ofFIG. 3. Note that, while an opaque coating of paint or anotheracceptable material is used, to insulate the dark field light pipeagainst light leakage, it is contemplated that all or a portion of thelight pipe can remain uncovered, particularly where the surface issufficiently well-polished to cause near-total internal reflection alongits length.

Referring now to FIG. 4, a CMOS, CCD or other electro-optical sensor 414is provided on a circuit board 412. A single ring illuminator of LEDs orother light sources 410 may also be provided on the board 412, orseparately from the board. The electro-optical sensor and light sources410 interconnect to a controller and/or image acquisition processorsimilar to those shown in FIG. 3. A dark field-illuminating light pipe420 is shown in cross-section. This surrounds the image sensor 414 andits associated optics 422, and is aligned with the light sources 410which are transmitted through the light pipe 420 to provide dark fieldillumination as described above. A transparent window 424 can beprovided in front of the optics 422 to protect the circuitry. As notedabove, the tip 430 of the light pipe 420 is angled at an angle A(approximately 45 degrees or more) so that light is reflected to passthrough an exposed thickness T along the inner perimeter of the lightpipe using internal reflection. The light transmits with the desiredlow-angle (or a high angle (over 45 degrees) respect to optical axiscenterline CL) dark field illumination pattern 440 that, in thisembodiment, is within a range DD of 0-1.25 inch. Note that the angle Aof the tip (approximately 45 degrees in this example) determines thegeneral angular range of light exiting the tip. There tends to be aspread of angles, in fact, and the prevailing angle of light may varysomewhat from the angle of the tip. The angle A of the tip may bealtered to generate the best angle and spread for light based upon thematerial used for the light pipe and it's wall thickness.

As also shown in FIG. 4 an extended bright field range DB of 3-4 inchesextends beyond the dark field range. In one embodiment, the bright fieldis not illuminated or can be illuminated by a variety of other externalsources. To this end, in an alternate embodiment, the dark field lightsource may further include an external bright field illuminator 450and/or 460. In one example, the bright field illuminator is a ring lightsource (with or without a light pipe) 450 that may or may not be mountedon the circuit board 412 (see board extensions shown in phantom). Theradial spacing of the optional, external bright field ring is variable.It may closely abut the dark field light pipe 420, or may be spaced awayfrom this light pipe as shown. According to another alternative, abright field illuminator 460 may be provided at another externallocation or locations. Note that the term “external” as used hereinshould be taken broadly to include a location that is inside the lumenof the dark field light pipe, such as, for example at the base of thepipe (adjacent to the circuit board, for example). This illuminator canbe provided as the only bright field illuminator, or in addition to thebright field ring 450.

With reference now to FIG. 5, a light pipe having only a bright fieldilluminator is shown. A circuit board, 510, carries LEDs 512 surroundinga sensor 514 with associated optics 516 and a window 518 to protectthem. A light pipe 520 communicates optically with the ring illuminatorLEDs 512. The tip 522 of the light pipe 520 can be rounded or flat andcan include a diffusing (frosted, for example) surface texture forenhanced scatter of bright field light. Note that other bright fieldlight pipes described herein can have similar tip constructions andsurfaces. The walls (inner and outer) of the light pipe 522 can becoated with an opaque, non-transmissive material or can remaintransmissive. Surrounding the outer circumference of the light pipe 520at various points are each of a set of individual directing rods/lenses530 (shown in partial cross-section for clarity of rod-like structure)that each optically communicate with individual or clusters of LEDs 532.Because the field of view of the sensor is limited, and the subject mustremain within the field of view to be properly read, the LEDs 532project aiming points, typically of a different, noticeable color ontothe item of interest. For example the aiming LEDs can project aprominent blue, red or green dot while the overall illumination is awhitish light. Note that the aiming point rods herein are circular incross section. However, they may be triangular, square or any othershape that adequately denotes an aiming point.

Two exemplary illumination patterns obtained with the bright fieldilluminator of FIG. 5 are shown, respectively in FIGS. 6 and 7. In FIG.6, the field of view of the camera sensor, shown as a dashed line 602,is rectangular, while the circular bright field illuminator projects acircular illumination pattern 604. This may be desirable where thesubject has a circular outline and the comers of the field of view arenot needed, or where the symbol/subject orientation is unknown. Thescanning application and/or image acquisition circuitry can be set toreject data within these comers to speed processing. To ensure that theuser aligns the illuminator properly with respect to the subject, fouraiming dots 610 are provided around the perimeter of the illuminationfield 604. These aiming dots give instant feedback to the user so thathe or she properly aims the illumination and field of view of theappliance onto the subject. Similarly, as shown in FIG. 7, where asquare light pipe is employed, a square illumination pattern 710 isprovided. This falls within the relative field of view 602. Again,aiming dots 712 are used to ensure proper direction of the appliance bythe user. In this embodiment, the dark field illumination range DB 1spans generally between approximately 0 and 12 inches from the tip 522of the light pipe. Other ranges are contemplated, of course.

FIG. 8 shows, in further detail, a nested light pipe arrangement inaccordance with an illustrative embodiment of this invention. An innerring of LEDs 802 and an outer ring of LEDs 804 are mounted on a circuitboard 806 that also includes a sensor 810. Associated optics for thesensor 812 are provided within a window area 814. As noted above, theouter light pipe 820 includes a tip 822 that is angled so as to produce,through an opening, thickness T an internally reflected beam of darkfield illumination with a span DD2 having a range of 0-1.25 inch in oneembodiment. The walls of the light pipe 820 are coated with anon-transmissive, opaque coating and the LEDs 804 of the ring are sealedby baffles 830 that isolate this illumination source with respect to theinner LEDs 802 and associated inner bright field light pipe 840. Thebright field light pipe is nested within the dark field light pipe 820and its tips 842 are recessed so as not to interfere with the openingthickness T. The tips 842 can be rounded, angled or flat. They producean appropriate bright field illumination pattern that, in thisembodiment, can extend a distance DB2 from 0-6 inches with respect tothe tip 822 of the dark field illuminator. In this manner, a brightfield subject can be contacted by the appliance and still adequatelyilluminated. Though, for contact viewing of a subject, the innerdiameter of the lumen formed by the light pipe assembly must be at leastas large in diameter as the subject being viewed. Nevertheless, incertain embodiments, it is contemplated that it is smaller and that thescanning application can include mechanisms for assembling portions ofan image formed as the appliance is moved around the image to take inall aspects of it when it is larger than the maximum field of viewafforded to the sensor. Again, as noted above, the controller candetermine either automatically or manually, whether to activate the darkfield illumination ring LEDs 804 or the bright field illumination ringLEDs 802 depending upon the subject and/or image quality obtained. A setof perimeter LEDs 850 communicate with lenses 852 in the form of rodsthat provide aiming dots as described above.

As also described generally above, the light pipe can be used torestrict the native field of view of the sensor. FIG. 9 shows a scanningappliance 902 having a rectangular cross-section light pipe 904. Thislight pipe can either be a dark field or bright field (or combination)illuminator. In this example, an item 910 includes a long, narrowsubject 912, namely a one-dimensional bar code. The illuminator projectsa pattern similar in size and shape to the bar code itself. In thismanner, when the user directs the illumination field to the item 910, heor she is naturally prompted to align the rectangular illuminationpattern with the bar code. That is, the user receives immediate feedbackas to the location of the reduced field of view, which appears as abright area that generally conforms to the subject outline. The subjectis better delineated by the reduced area, and any information outsidethis area can be omitted from the acquisition data stream, thus speedingimage processing.

With reference to FIG. 10, the overall field of view of the camera,shown as dashed line 1002, is a large square while the illumination areais a substantially narrower rectangle 1004. Again, this rectangleconforms to the shape of a one-dimensional bar code in this example. Avariety of other shapes and sizes can be provided for a selectiveillumination area with respect to the overall field of view. Smallcircles, ovals, squares and complex geometric patterns are allcontemplated. Appropriately shaped light pipes are constructed toconform to these shapes. Likewise, these light pipes can include darkfield, bright field or a combination of bright and dark field structuresas described above. Similarly, the narrowed-field of view (or “reducedfield of view”) illuminator can include aiming dots to further assistalignment on the subject.

Referring now to FIG. 11, in the example of a bright field illuminator,a ring of LEDs 1102 is mounted on a circuit board 1104, which alsoincludes a sensor 1106. The board is interconnected with a controller orimage acquisition device that includes scanning software applications. Abright field illumination pattern extends a distance DB3 from the tip ofthe light pipe 1120. In this example the distance DB3 is approximately6-8 inches. However other distances are expressly contemplated. Thescanning software application is adapted to reject pixels outside of thedesired field of view either through knowledge of pixel addresses thatfall outside of the desired field or because these pixels are notappropriately illuminated and are therefore rejected (e.g. they are toodark). An appropriate optics 1110 and window 1112 is also provided aswell as a light pipe 1120 that is shaped as an elongated rectangle.

Referring now to FIGS. 12 and 13, an alternate embodiment of a scanningsystem 1200 including an active dark field illumination system is shown.Here, rather than providing the illumination ring at an end of a lightpipe opposite the surface to be illuminated and directing the lightthrough the pipe, as described with reference to FIGS. 3, 4 and 8 above,an illumination ring 1202 is mounted inside of an opaque cover orreceptacle 1204 at the end of a pipe 1206 adjacent the surface to beilluminated. The purpose of the pipe 1206 is to position theillumination ring 1202 near the surface to be illuminated, and the pipe1206 therefore does not need to be constructed of a transmissivematerial as described above. However, transparent tube material aids invisually placing the reader over the code to be read The opaque cover1204 is sized and dimensioned to receive the illumination ring 1202, andincludes a top opaque surface 1220, and an outer opaque surface 1224.The inner surface 1226 is either left open, or includes a plurality ofmounting holes for receiving individual lighting elements such as lightemitting diodes (LEDs) which form the illumination ring 1202. The opaquesurfaces 1220 and 1224 prevent light from the illumination ring 1202from being transmitted directly onto an underlying illumination surfaceadjacent the scanning system 1200, and directs light from theillumination ring 1202 instead inward, toward the center of the lightpipe 1206. As shown in FIG. 13, as the light exits the light pipe 1206,it is therefore angled, providing dark field illumination to the surfaceto be illuminated. As described above, bright field illuminationelements could also be provided in conjunction with the active darkfield illumination pipe.

As described above with reference to FIG. 3, the illumination ring 1202of FIG. 13, as well as any of the dark field illumination rings andarcuate illuminators shown in FIGS. 3, 3A, 4, and 8, can be segmentedinto individually-controllable segments. These illuminators aredescribed collectively hereafter as “illumination rings”. However, thediscussion below applies equally to both rings and arcuate lightingsegments, as described above with reference to FIG. 3A. Theindividually-controllable segments can comprise four segments, such asthe quadrants 380, 382, 384 and 386 shown in FIG. 3, or be segmented ina number of alternate ways. For example, in alternate embodiments, thering illuminator may be divided into halves, or any larger number ofsegments can be employed, including segments comprising individual LEDs.Irrespective of the selected segmentation, the segments can beseparately controlled or addressed by the controller 370 (FIG. 3) toattain a desired dark field illumination pattern, as described below.The controller 370 can further selectively activate or modulate thelight emitted from any of these elements, vary the exposure time of thesensor 330, or vary the focal point of the camera, also as describedbelow.

Referring again to FIGS. 1, 2 and 3, and also to FIG. 14, a blockdiagram of a control system for use in controlling a ring illuminator asdiscussed with respect to FIGS. 3, 4, 8, and 13 is shown. As describedabove, the scanning device (100, 200, or 1200) includes onboardprocessing 109 including a scanning application 113. The processor 109includes a controller 370, connected to the ring illuminator 382 forcontrolling the activation of lighting elements 380, 382, 384, and 386.The controller 370 is further connected to an image sensor 330 foracquiring image data, to a memory 371 for storing and retrieving imagedata, as well as lighting selection data, as described below, and to atransmitter/receiver 372 for transmitting data to and receiving datafrom a host computer 112. A user select input 374 can also be connectedto provide data to the controller 370 to provide a manual selection oflighting conditions or other parameters as described below.

In operation, the on-board processing board 109 can be operated toassure adequate or optimized lighting conditions based upon anevaluation of feedback data for both handheld (FIGS. 1 and 12) and fixedapplications (FIG. 2). To achieve such conditions, the scan lighting iscontrolled by the scanning application 113 and controller 370 toindividually control each of the light segments, such as the quadrants380, 382, 384, and 386, to selectively activate or deactivate theindividual segments, dim or brighten selected segments, or to vary theexposure time of the lighting on the illumination surface. Re-orientingthe applied lighting can be useful, for example, when illuminatingmetallic or curved surfaces, or when illuminating highly reflectivesurfaces. When illuminating metallic or similar grained surfaces, forexample, it has been observed that illumination is often more effectivewhen oriented along the grain of the material. With the ability to dimor deactivate illumination across the grain, a significantly improvedimage can be attained. Furthermore, when illuminating curved surfaces,improved results can be attained by illuminating the surface in aselected direction. Similarly, varying lighting conditions can bebeneficial when working with reflective surfaces.

The scanning application 113 can entail, for example an initializationprocess in which the individually-controlled light segments 380, 382,384, and 386 are cycled through a variety of preset on/off combinationsis performed until the quality of the image is determined to besufficient for evaluating a bar code or other symbol, or to determinewhich of the settings provides the best image quality. In this process,feedback in the form of image data acquired by the sensor 330 isevaluated by the controller 370. For example, the image data acquired bythe sensor 330 can be processed for each different available setting ofthe individual quadrants 380, 382, 384, and 386, and when an acceptableand/or optimal image is attained, that particular setting can beselected for on-going data acquisition. Image optimization can be basedupon recognition of known fiducials or detection of maximum contrastover a sufficiently wide portion of the viewed area of interest.

In a fixed-camera arrangement, this adjustment process can typically becarried out once, and the selected setting can be applied to eachsuccessive acquired image. Alternatively, in handheld scanningapplications, where angles and orientations of the appliance relative tothe item are likely to change, the adjustments can also be madedynamically for each scan, or selectively performed by the operator whoselects the initialization mode, for example, when environmentalconditions change. Even in handheld operations, however, a fixed settingcan be effective where the scan will always be taken from approximatelythe same location, and/or in the same environmental conditions, or in aknown subset of available conditions.

In embodiments which include both bright and dark field illumination, asshown, for example, in FIGS. 3, 4, and 8, the scan application 113 canalso be programmed to select between dark field or bright fieldillumination depending on which type of illumination best suits aparticular application. The selection between bright and dark fieldillumination can be made automatically by the image processor basedfeedback, as described above, or selected manually by the operator.

Referring again to FIGS. 1, 2, 3, 13 and particularly to FIG. 15, a flowchart illustrating a typical process for selecting lighting conditionsis shown. As described above, the scanning system 100 can be initializedusing a predetermined initial lighting configuration 1301, which can be,for example, a series of predetermined lighting variations, or,alternatively, a pre-selected general purpose setting, or a “cached”setting retrieved from the memory component 371. The stored setting canbe, for example, the setting from the last successful or a previoussuccessful decode attempt, a setting which has been determinedstatistically to be typically successful in the environment, or anaverage setting determined over a series of successful attempts. Theinitial setting can activate or deactivate variousindividually-controlled light segments such as the quadrants 380, 382,384, and 386 of an illumination ring, activate or deactivate dark orbright field lighting, or modulate the brightness levels of any of theselighting elements by varying an analog signal applied to the lightsegments, applying a pulse-width modulated signal, or in various otherways which will be apparent to those of skill in the art. The exposuretime of the sensor 330, and the focal length of the camera can also bevaried to obtain optimal conditions.

After the symbol is illuminated, an image data set is acquired by thesensor 330 in step 1302, and this data set is evaluated in step 1303.Evaluation of the image data in step 1303 can comprise an attempt todecode the symbol, or, in the alternative, comprise a statisticalevaluation of the acquired data set based on histograms or otherstatistical analyses known in the art to determine whether the contrastbetween white and black pixels in the acquired data is within anexpected range. If the data set acquired in step 1302 is determined tobe suitable for decoding, a “good read” has been established and, instep 1306, the symbol is decoded and the process is stopped. Thesettings established in step 1301 can also be stored or cached in thememory component 371 for later retrieval, as described above.

Data suitable for decoding can be based on a full read of the symbol, oron a partial read, in which data is reconstructed using error-correctingmethods such as parity checks, check sums, and known symbol criteriasuch as the number of characters expected, or other parameters whichwill be apparent to those of skill in the art.

If the image data set is not suitable for decoding, in step 1304, thecontroller 370 changes the lighting settings by varying the selection ofbright or dark field illumination, varying the set ofindividually-controllable light elements which are activated ordeactivated, or by modifying the brightness of the light provided. Theseparameters can be determined, as described above, based on apre-established set of parameters, by an analysis of the acquired dataset, or by user selection. After new settings are selected in step 1305,a new image data set is acquired in step 1302, and steps 1303-1305 arerepeated until a “good” data set is acquired, and the symbol is decoded.

Although the variation of lighting has been described above as anautomatically-controlled process, as shown in FIG. 14, the controller370 can also receive manual commands from the user through a user selectinput 374. The user select input can receive, for example, an inputsignal from a single or multi-position switch provided on the scanningdevice, an input provided through other software or hardware-based userinterfaces provided on the scanning device, or through software on acomputer 112 connected to the controller through thetransmitter/receiver 372. Various other ways for providing an interfacefor users to select lighting parameters will be apparent to those ofskill in the art. Through the user select input 374, the user canmanually choose, for example, to activate individual quadrants orsegments in the illumination ring, select a predetermined sequence ofsegments, vary the brightness of the illumination, select between brightand dark field illumination, or re-start an initialization process whichprovides a predetermined set of variable illuminations, as describedabove. Other manual selections, as will be apparent to those of skill inthe art, could be provided through a user input.

The foregoing has been a detailed description of illustrativeembodiments of this invention. Various modifications and additions canbe made without departing from the spirit and scope thereof For example,although a block diagram comprising a specific configuration for thecontrol system is shown, it will be apparent to those of skill in theart that this is a simplified representation and that various methods ofconstructing the hardware can be used. Additionally, it is expresslycontemplated that any of the features described in any of the aboveembodiments can be combined with other features to produce various lightpipe arrangements. Likewise, a wide variety of data processing devices,scanning application programs and/or hardware systems can beincorporated to control illumination and acquire images. Finally, thelight pipes described herein can be provided with integral illuminatorson a circuit board that also includes a sensor and control functionsthat allow the sensor to communicate with the illuminator.Alternatively, the illuminator, light pipe and camera can all beseparate components that are interconnected via one or more controllers,or all connected to a common computer or processor through appropriateinterfaces. Various combinations of sensor, optics, illuminator andlight pipes are all expressly contemplated. For example, sensors may beprovided on the same circuit board as the processor and the lightsources, or any/all of these components. can be separate. Appropriateinterfaces and attachment mechanisms, that should be clear to those ofordinary skill, can be provided to facilitate interaction between thevarious components described herein. In addition, while the bright fieldlight pipe is described as nested within the dark field light pipe, itis expressly contemplated that these two pipes can be reversed bypositioning the bright field illuminator outside the dark field lightpipe. Likewise, either light pipe (or light source therefor) may bedefined as a broken ring, with non-illuminated segments along theirperimeters. Accordingly, this description is meant to be taken only byway of example and not to otherwise limit the scope of the invention.

1. A method for decoding an encoded data symbol, the method comprising: providing a light source comprising a plurality of individually-controllable lighting elements for providing low angle dark field illumination; activating an image sensor for detecting image data reflected from an encoded data symbol when the encoded data symbol is illuminated by the light source; and providing a controller connected to each of the individually-controllable lighting elements, the controller being programmed for: selectively activating the individually-controllable lighting elements to vary the direction of the low angle dark field illumination provided by the light source; evaluating the detected image data and determining whether the detected image data is sufficient to decode the encoded data symbol; varying the low angle dark field illumination provided by the light source until the detected image data is sufficient to decode the encoded data symbol; and processing the image data detected by the image sensor.
 2. The method according to claim 1, wherein the individually controllable lighting elements comprise portions of at least one of a circular ring, an oval ring, a rectangular ring, and an elliptical ring.
 3. The method according to claim 1, wherein the individually-controllable lighting elements comprise a plurality of electrically-connected individual light elements.
 4. The method according to claim 1, further including the controller evaluating the image data detected by the image sensor and varying the dark field illumination to optimize symbol decoding.
 5. The method according to claim 1, wherein the dark field light source comprises a passive light pipe or an active light pipe.
 6. The method according to claim 1, further including providing a manual control connected to the controller for manually selecting at least one of the individually-controllable lighting elements to be activated.
 7. The method according to claim 1, further including providing a memory component for storing data corresponding to the individually-controllable lighting elements.
 8. The method according to claim 1, further including the controller varying an exposure time of the image sensor.
 9. The method according to claim 1, further including the controller determining whether the image data detected is sufficient to decode the encoded data symbol based on a statistical analysis of the image data detected.
 10. The method according to claim 1, further including the controller determining whether the image data detected is sufficient to decode the encoded data symbol based on an attempt to decode the encoded data symbol.
 11. The method according to claim 1, wherein the image sensor is connected to the controller for detecting light reflected from the encoded data symbol and for providing feedback to the controller for varying lighting conditions.
 12. The method according to claim 1, wherein the dark field light source is arcuate.
 13. The method of claim 1, further including providing a bright field light source for providing bright field illumination; wherein the controller is connected to the bright field illumination source and programmed for selectively activating the bright field light source.
 14. The method according to claim 13, further including providing a handheld enclosure for housing the dark field light source, the bright field light source, and the image sensor.
 15. The method according to claim 13, further including providing a fixed mount enclosure for housing the dark field light source, the bright field light source, and the image sensor.
 16. A method for decoding an encoded data symbol, the method comprising the steps of: (a) providing a plurality of individually-controllable lighting elements arranged around the encoded data symbol to provide low-angle dark field illumination; (b) providing a bright field illuminator directed at the encoded data symbol to provide bright field illumination; (c) selectively illuminating the encoded data symbol with at least one of the individually-controllable lighting elements; (d) acquiring an image data set; (e) evaluating the image data set for determining suitability for decoding; (f) selectively varying a lighting parameter for varying the light emitted from the individually-controllable lighting elements to vary the direction of the low-angle dark field illumination on the encoded data symbol and selectively activating the bright field illuminator; and (g) repeating steps (d), (e) and (f) until the image data set is suitable for decoding.
 17. The method according to claim 16, further including the step of arranging the individually controllable lighting elements in quadrants.
 18. The method according to claim 17, wherein wherein successive occurrences of step (c) further includes sequentially activating at least one combination of the quadrants.
 19. The method according to claim 16, further including the step of storing the lighting parameter found to be suitable for decoding the image data set.
 20. The method according to claim 16, wherein step (c) further includes retrieving a stored illumination setting.
 21. The method according to claim 16, wherein step (a) further includes retrieving default parameters for activating each of the lighting elements.
 22. The method according to claim 16, wherein step (e) further includes evaluating the image date set for decoding the encoded data symbol.
 23. The method according to claim 16, wherein step (e) further includes evaluating the image data set for evaluating a relative concentration of light and dark pixels.
 24. The method according to claim 16, wherein step (f) further includes selectively varying the light emitted by modulating a signal applied to at least one of the individually-controllable lighting elements to vary a brightness of the illumination.
 25. The method according to claim 16, wherein step (f) further includes selectively varying an exposure time for illuminating the encoded data symbol.
 26. The method according to claim 16, wherein step (f) further includes selectively varying a focus parameter.
 27. The method according to claim 16, wherein step (f) further includes selectively activating at least one of the individually-controllable lighting elements.
 28. The method according to claim 16, wherein step (a) further includes angling the light emitted from the individually-controllable lighting elements to provide the low angle dark field illumination.
 29. A method comprising: using a ring light source, projecting low angle dark field illumination to an adjacent surface including a symbol to be decoded; providing a controller connected to the ring light source and using the controller for selectively varying the direction of the low angle dark field illumination provided from the ring light source; using an image sensor connected to the controller, the image sensor acquiring image data of the symbol, wherein the controller is programmed for: evaluating the acquired image data and determining whether the image data is sufficient to decode the symbol; and varying the light projected from the ring light source until the image data is sufficient to decode the symbol.
 30. The method according to claim 29, further comprising using a bright field light source, projecting bright field illumination to the adjacent surface, wherein the controller is further programmed for selectively activating the bright field light source to illuminate the symbol. 